Method and apparatus for making non-woven twill webs



B. ROMANIN Dec. 26, 1967 METHOD AND APPARATUS FOR MAKING NON-WOVEN TWILLWEBS Filed May 21, 1963 w I j 21 k L N m 4 a s N M 7 W0 4 e m MM a M R jMw M91 @v .3 iivw United States Patent M 3,360,410 METHOD AND APPARATUSFOR MAKING NON-WOVEN TWILL WEBS Bruno Romania, 8 Via Vincenzo Monti,Milan, Italy Filed May 21, 1963, Ser. No. 282,054 Claims priority,application Italy, May 29, 1962, 10,623/ 62, Patent 669,075 Claims. (Cl.156-172) This invention relates generally to the manufacture ofnon-woven web or fabric material, wherein the weave or network includesthreads or yarns arranged diagonally of the length of the material. Suchtwill or biased webs or fabrics possess certain advantageous properties,as known to those skilled in the art, such as a remarkable elasticityand deformabilify, in both longitudinal and transverse directions, owingto the diagonal arrangement of the yarns by which it is made. Such twillwebs are advantageously used, for example, as reinforcement for tires,as reinforcement and support for artificial leather, plastic sheets andother pliable sheet compound material such as upholstery covering, andso on.

According to current procedures, said twill webs are cut fromconventionally produced fabrics, wherein weft and warp yarns arearranged lengthwise and transversely of the manufactured woven ornon-woven networks.

Such procedures lead to .a substantial waste of material and the cutportions are confined within the dimension of a diagonal of the producednetwork.

It is therefore an object of this invention to provide a new method ofproducing a twill web wherein the several network forming yarns areevenly diagonally arranged in respect of the length of the article ofmanufacture.

Another object of the invention is to provide a method of producing acontinuous strip material having parallel side edges and including anetwork of yarns or threads arranged diagonally to and intercrossing inthe space defined by said side edges in superimposed relationship, toform a non-woven twill web.

A further object of this invention is to provide a new and advantageousapparatus for continuous manufacture of such non-woven twill web, andcapable of continuous mass production thereof; in which reciprocatingparts are not included; in which continuously moving spool carrier meansare crculated about a plane defined by straight parallel side yarns orcords; and in which the yarns or threads continuously supplied by aplurality of spools supported by said spool carrier are guidely arrangedin alternate diagonal directions between and about the parallel sideyarns or cords.

More particularly the invention provides a method of forming a non-woventwill web, which comprises feeding at a given speed two straightparallel essentially inextensible and stress resisting side yarns atlocations defining the parallel side edges of the network to beproduced, continuously revolving or circulating a plurality of webforming yarn supplies along a path encircling both side yarns, guidelyfeeding the web forming yarns, at locations essentially adjacent to theplane defined by said side yarns and continuously circulating about saidplane-whereby each web forming yarn is caused to be wound about bothsaid side yarns and to be arranged essentially as a flattened helicalcoil thereaboutmoving the fed web forming yarns together with said sidestraight yarns in said plane, and joining together the resultingsuperimposed and intercrossing web forming yarns at a number oflocations where said latter yarns intercross.

The connection to each other of said web forming yarns at said number oflocations, and preferably at all points where said yarns intercross, canbe made by applying current knowledge of the art, and therefore suchstep'of the method will not hereinafter be described in detail. For

3,360,410 Patented Dec. 26, 1967 example, suitable binding agents may beused therefor. In the case that such yarns consist of thermoplasticmaterial, such connection may be performed by combined heating andpressure application, by feeding the produced network betweencounter-rotating heated roller or conveyor means, for example. Stillfurther, the action of heat and/ or pressure may be combined with theuse of suitable solvents and/or binding agents, according to the natureof the web forming yarns.

In the case that the considered non-Woven web is designed to be made useof as reinforcement of a reinforced sheet material, the sheet materialor materials of the compound article of manufacture may be made use offor securing the intercrossing yarns of the web in their rela tivearrangement. Therefore the said non-woven web may be fed, concurrentlywith said sheet material or materials, into the nip of counter-rotatingrollers or conveyers, according to current knowledge, and bound thereto,by means of binding agents and/ or upon combined action of heat andpressure, according to the nature and character of the combined yarn andsheet material.

These and other objects and advantages of this invention will be bestunderstood from the following'specification in conjunction with theaccompanying drawing wherein,

FIGURE 1 is a somewhat diagrammatical view from above of an apparatusconstructed and operated according to the invention;

FIGURE 2 is a similar side view thereof;

FIGURE 3 is a vertical sectional view taken through line 333-3 ofFIG. 1. 7

Referring now to the drawing, the apparatus includes guide and feedingmeans for continuously moving two side yarns 10 and 11, in the directionindicated by arrows A, at a given speed. Such yarns extend parallel toeach other and define a horizontal plane therebetween and includingthese side yarns, and are made of tension resisting material, such as atwine or cord of suitable natural or man-made fibers or filaments.Metallic wire might be made use of for forming said side yarns 10 and11, if desired. Known means (not shown) may be used for suitably keepingunder tension said side yarns 10 and 11, which are fed in the workingportion of the apparatus through tubular parallel components 12 and 13,respectively. 1

The means for drawing side yarns 10 and 11 are not shown or described indetail, as such means are well known to those skilled in the art. Forexample, the draw ing means may be of the type shown and described inHolland US. Patent No. 2,696,243 wherein endless bands 38 supported byand continuously revolving about pulleys 24, 34, 40 and 42 are shown anddescribed for defining parallel side edge components which are movedconcurs rently with an unwoven web formed thereabout.

Such tubular components 12 and 13, in addition, define the shafts ofsymmetrical sets of pulleys or of gears 14 and 15, respectively, drivenat another given speed, and supporting and driving conveyors 16 whichare cont1nuously revolved, in direction B for example, at said anothergiven speed, about and essentially parallel to opposite surfaces of theplane defined by said side yarns 10 and 11-.- Conveyors 16, the numberof which might of three, for example, act as carrier means for aplurality of Web forming supplies, such as bobbins 17, for example, andof shaped or bent guide tubes 19, each having an inlet located adjacentto a bobbin 17 to receive the yarn supplied therefrom, and an outletlocated substantially adjacent the plane defined by said side yarns 10and 11.

The structural details of the conveyors and their. driving means havenot been shown, as these are well known to those skilled in the art. Forexample, aweft holding t a endless conveyor is shown in British PatentNo. 440,191

of 1935. In this British patent, a weft holding conveyor is shown ascomprising an endless chain structure, the conveying path of whichcomprises upper and lower straight portions interconnected bysubstantially circular end portions.

Upon rotation of said conveyors 16, therefore, each guide tube outletwill continuously travel along a closed path circumscribing the plane,and which includes two straight parallel logs above and respectivelybelow the said plane defined by side yarns and 11, and two short radiushalf-circle portions having their centers in or essentially in said sideyarns.

It will be understood, however, that the terms above and below, asreferred to the plane defined by said side yarns 10 and 11, are to beassumed as meaning above and beneath said plane, supposing that suchplane would be horizontal, as shown in the accompanying drawing. Sucharrangement of saidplane, i.e., the arrangement of said side yarns 10and 11 horizontal and at the same level, is believed convenient but notcritical in view of carrying out of the invention. Differingarrangements, such as a vertical arrangement of downwardly fed sideyarns, is, however, possible and even convenient for facilitatingfeedingof web forming yarns together with said side yarns at said given speed,for example.

Therefore the above considered terms above and below will be taken, asthis description proceeds and in the appended claims, in their broadestmeaning, and in particular as generally indicating the one andrespectively the other surface of said plane, however arranged withrespect to the horizontal.

Supposing now that the said straight and parallel side yarns 10 and 11are continuously lengthwise progressed in direction A at a given speed,and that said conveyors 16 and therefore said spools 17 and guide tubes19 are continuously circulatedin direction B at another given speed, theweb forming yarns likewise continuously unwound from and supplied byspools 17 will be in turn fed at 18 from the outlets of guide tubes 19and helically wound about the side yarns 10 and 11, to form flat helicalcoils including straight portions 20 and 21 above and respectively belowsaid plane as shown in FIG. 1.

The pitch of said coils will be a function of the ratio of the givenspeed of feeding in direction A, of side yarns 10 and 11 and the speedof the helically arranged web forming yarns wound thereabout and carriedthereby, namely of the speed at which the outlets of guide tubes 19travel in direction B in the straight legs of the conveyor paths, aboveand below the plane. In the case that said given speed of feeding indirection A and of traveling in direction B above and below said planeare equal, both portions 20 and 21 of each formed coil will form anangle of 45 with respect to the said edge forming side yarns 10 and 11and therefore with respect to the length of the web thus produced. Bysuitable adjustment of the speed ratio, the inclination of thediagonally arranged web forming yarns may be modified at will.

' The means for insuring concurrent driving of endless chain conveyors-17, rollers 23 and 24, described hereinafter, and side yarns 10 and 11have not been shown or described in detail. Such means are known tothose skilled in the art of mechanical driving of rotary v components,and preferablycan consist of conventional gear means by which the shaftsof gears 14 and 15, the shafts of rollers 23 and '24, and the pulleys(notshown) about which the side yarns are moved, are mechanicallyinterconnected. The gear means can include conventional gear boxeshaving replaceable or interchangeable gears,.

such as commonly used in machine tools, for modifying, at will, thetransmission ratio between the various shafts and therefore providingthe desired ratios between the .guide means in direction B may beincreased with respect to the speed at which the formed non-wovennetwork is moved in direction A. The portions 20 and 21 of the flatcoils formed by each web forming yarns will form a greater angle withrespect to the side yarns 10 and 11. A web transversely more rigid willhe therefore produced, such web being, however, more resilient as to itslongitudinal direction. Such latter result, if deemed as objectionable,may be overcome by providing additional parallel straight lengthwisearranged reinforcing yarns, such as diagrammatically indicated at 22 inFIG. 1, for example.

Any web forming yarn, as moved outside its respective guide tube 19,will assume its desired coil arrangement about the side yarns 10 and 11,as laid at 18 in the plane or essentially in the plane defined by theside. Near the web formation or working zone at 18, counterrotatingrollers 23 and 24 are located and the web is fed in the nip of rollers23 and 24, whereby the portions 20 of said web forming yarns, above thesaid plane, are pressed against the underlying portions 21 to form thedesired flat network, wherein the intercrossing diagonal portions 20 and21 of the web yarns are caused to contact to one another, preparatory tointerconnection of the non-woven network components.

Such interconnection may be performed by applying current knowledge, byheat process and/or by using proper binding agents. Said interconnectionmay be performed upon passage between said rollers 23 and 24, forexample, or downstream of said rollers and upon passage of the networkbetween conveyors (not shown), for example, for ensuring proper pressureon the superimposed components until setting of the heat and/or binderprocessed web material.

In the nip of rollers 23 and 24, suitable sheet material, such as asynthetic film material, may be fed above and/ or below the networkformed at 18, if desired, and bound to said network components.

The number of the intercrossing portions 20 and 21 in the thus formednon-woven web is obviously a function of the number of spools or otherweb forming yarn supplies carried by the circulating spool carrierconveyor means, such as embodied by conveyors 16, and the closeness ofthe network, i.e., the spacing between its components, is a function ofthe spacing between the outlets of the guide tubes 19. For simplicityand clearness sake, in the figures of the accompanying drawings there isdiagrammatically shown an apparatus the spool carried assembly of whichsupports relatively few and spaced spools 17 and related guide tubes 19.It will be evident to those skilled in the art that such spool carrierassembly might be suitably constructed for supporting and circulating amuch greater number of spools and guide tubes, placed close to eachother, within the limits or diametral dimension of individual webforming yarns supplies.

In addition, while in the accompanying drawing there is shown anapparatus having a spool carrier circulating assembly adapted to carryone range of spools 17, it will be evident that such assembly mightinclude two or more ranges of said spools, suitably arranged in thedirection in which the formed web is fed, each spool in any range beingprovided with a related guide tube, and each guide tube being providedwith an outlet located to supply the web forming yarn from the relatedspool in the location indicated at 18 where the non-woven web is formedabout the side yarns 10 and 11.

It will be noted that the desired mechanism does not includereciprocating parts or components for supplying and arranging theseveral yarns in the non-woven nettinuous operation at high productionspeeds.

From the above, and upon a consideration of the accompanying drawing itwill be evident to those familiar with the art that the inventionprovides a new and advantageous method for economically mass producing atwill or biased web or fabric by continuously feeding a plurality of webforming yarns along a closed path transverse to and circumscribing anideal strip-like plane defined by parallel side edges, materiallyembodied by parallel stretched side yarns, by causing each fed webforming yarns to be coiled about said plane, namely about said stretchedside yarns, in an essentially flat helical arrangement, by causing theportions of said web forming yarns, laid at one side of said plane, tocontact intercrossing portions of the web forming yarns, laid at theopposite side of said plane, and by joining together such portions whereintercrossing-whereby a non-Woven twill including intercrossed yarnsarranged diagonally with respect to the side edges thereof isproduced-while all said yarns are continuously fed in the plane and inthe direction defined by said side edges.

The side portions of the web, wherein the said side yarns are enclosedwithin the coiled web forming yarns, do not obviously possess theresiliency and the ability of meeting substantial deformations, astypically biased fabrics do, may be obviously cut off upon setting ofthe web in its final configuration, namely as the overlapping webforming yarns thereof are joined to each other where intercrossing.

It is further evident that this invention provides a new, simple andcontinuously operating apparatus for producing a non-woven web materialin the form of a continuous sheet having a given width, and consistingof evenly arranged pluralities of intercrossing web forming yarns, saidapparatus comprising means for continuously circulating yarn suppliesand guide means in a closed path circumscribing two parallel materialedge defining side yarns for winding said Web forming yarns about saidside yarns, means for continuously progressing all said web forming andside yarns in the direction defined by said side yarns, so that webforming yarns will assume the configuration of coils flattened in theplane defined within said side yarns, and means for causing theoverlapping portions of said web forming yarns to contact to each other,prep-aratory to connection to each other where intercrossing.

It is further believed to be evident that the present invention providesa plurality of advantageous features, and it will be understood thateach of the new features described and shown and any combination thereofmay also find useful application in other methods and manufacturingprocedures, differing from the one described, by applying currentknowledge.

Having thus described the invention, what I claim as new and desire tohave protected by Letters Patent is:

1. In the method of continuously producing a non woven web havingparallel side edges and a network of web-forming yarn portionsdiagonally arranged with respect to the side edges and overlapping andintersecting in the plane defined by the side edges, and in which yarns,including a pair of straight side yarns extending parallel to the sideedges of the plane defining the side edges, are progressively drawn fromsupplies thereof longitudinally and in substantially parallel relationto the side edges of the plane, a plurality of web-forming yarn suppliesare continuously circulated in a closed path circumscribing the planedefined by the side yarns and transversely of the side yarns, theweb-forming yarns are continuously drawn from the supplies thereof andprogressively drawn longitudinally with the side yarns, while beinglayed diagonally of the side yarns on opposite surfaces of the planeextending between the side yarns, and diagonally extending, andweb-forming yarns on opposite surfaces of the plane are subjected tobonding pressure at intersections thereof of said web-forming yarns toform the flattened helices: the improvement in which the web-formingyarn supplies are continuously circulated in a closed path including apair of rectilinear portions parallel to and immediately adjacentopposite surfaces of said plane and including semicircular short radiusportions extending about said parallel side edges and interconnectingsaid rectilinear portions.

2. The improvement claim in claim 1, including the steps of moving saidlongitudinal and web-forming yarns in said plane at a first given speed;circulating said supplies of web-forming yarn around said path at asecond given speed; and adjusting the ratio of said first and secondgiven speeds to obtain a selected pitch of said flattened helices and,correspondingly, a selected angle between said web-forming yarns andsaid longitudiinal yarns.

3. An apparatus for continuously producing a nonwoven web havingparallel side edges and a network of web-forming yarn portionsdiagonally arranged with re spect to the side edges and overlapping andintersecting in the plane defined by the side edges, and of the typeincluding means for drawing longitudinal yarns, including means fordrawing and guiding yarns extending parallel to the side edges of theplane, including a pair of straight side yarns definining the sideedges, progressively from supplies thereof and longitudinally and insubstantially parallel relation to the side edges of the plane, aplurality of web-forming yarn supplies, respective guide meansassociated with said yarn supplies, means continuously circulating saidweb-forming yarn supplies and respective guide means in a closed pathcircumscribing the plane defined by the side yarns and extendingtransversely of the said yarns, means for continuously drawingweb-forming yarns for the supplies thereof through the respective guidemeans and progressively drawing the web-forming yarns longitudinallywith the side yarns to lay the web-forming yarn diagonally of the sideyarns on opposite surfaces of the plane extending between the side yarnsto form flattened helices embracing the side yarns and the planeextending therebetween, and means applying bonding pressure to thediagonally extending web-forming yarns on opposite surfaces of the planeat intersections thereof to interconnect the same at such intersectionsto form the flattened helices: the improvement comprising, incombination, said guide means comprising respective tubular guides eachextending substantially parallel to said plane and to said side yarns,each tubular guide having a yarn exit end surved toward said plane andterminating closely adjacent a surface of said plane.

4-. The improvement as claimed in claim 3, said means for guiding saidpair of side yarns defining the opposite longitudinal side edges of theweb formation plane comprising a pair of relatively elongated guidetubes each axially aligned with a respective side edge of said formationplane, each side edge defining longitudinal yarn extending in guidedrelation through a respective guide tube; said means circulating saidsupplies of web-forming yarns comprising endless conveyor meansextending around rotary conveyor members rotatable about said guidetubes as axes.

5. The improvement as claimed in claim 3, in which said means applyingpressure to the intersecting helices comprises a pair of counterrotating rollers extending transversely of said plane, each roller beingadjacent a respective opposite surface of the web and said rollersconjointly defining a nip through which said longitudinal andweb-forming yarns extend.

References Cited UNITED STATES PATENTS 2,696,243 12/1954 Holland 1561722,797,728 7/1957 Slayteretal. 156-180XR 2,847,056 8/1958 Vanlaer 156433XR FOREIGN PATENTS 440,191 12/1935 Great Britain.

EARL M. BERGERT, Primary Examiner. P. DIER, Assistant Examiner.

1. IN THE METHOD OF CONTINUOUSLY PRODUCING A NONWOVEN WEB HAVINGPARALLEL SIDE EDGES AND A NETWORK OF WEB-FORMING YARN PORTIONSDIAGONALLY ARRANGED WITH RESPECT TO THE SIDE EDGES AND OVERLAPPING ANDINTERSECTING IN THE PLANE DEFINED BY THE SIDE EDGES, AND IN WHICH YARNS,INCLUDING A PAIR OF STRAIGHT SIDE YARNS EXTENDING PARALLEL TO THE SIDEEDGES OF THE PLANE DEFINING THE SIDE EDGES, ARE PROGRESSIVELY DRAWN FROMSUPPLIES THEREOF LONGITUDINALLY AND IN SUBSTANTIALLY PARALLEL RELATIONTO THE SIDE EDGES OF THE PLANE, A PLURALITY OF WEB-FORMING YARN SUPPLIESARE CONTINUOUSLY CIRCULATED IN A CLOSED PATH CIRCUMSCRIBING THE PLANEDEFINED BY THE SIDE YARNS AND TRANSVERSELY OF THE SIDE YARNS, THEWEB-FORMING YARNS ARE CONTINUOUSLY DRAWN FROM THE SUPPLIES THEREOF ANDPROGRESSIVELY DRAWN LONGITUDINALLY WITH THE SIDE YARNS, WHILE BEINGLAYED DIAGONALLY OF THE SIDE YARNS ON OPPOSITE SURFACES OF THE PLANEEXTENDING BETWEEN THE SIDE YARNS, AND DIAGONALLY EXTENDING, ANDWEB-FORMING YARNS ON OPPOSITE SURFACES OF THE PLANE ARE SUBJECTED TOBONDING PRESSURE AT INTERSECTIONS THEREOF OF SAID WEB-FORMING YARNS TOFORM THE FLATTENED HELICES: THE IMPROVEMENT IN WHICH THE WEB-FORMINGYARN SUPPLIES ARE CONTINUOUSLY CIRCULATED IN A CLOSED PATH INCLUDING APAIR OF RECTILINEAR PORTIONS PARALLEL TO AND IMMEDIATELY ADJACENTOPPOSITE SURFACES OF SAID PLANE AND INCLUDING SEMICIRCULAR SHORT RADIUSPORTIONS EXTENDING ABOUT SAID PARALLEL SIDE EDGES, AND INTERCONNECTINGSAID RECTILINEAR PORTIONS.